Method and apparatus for controlling combustion quality of a gaseous-fuelled internal combustion engine

• US 7,325,529 B2
• Filed: 04/04/2006
• Issued: 02/05/2008
• Est. Priority Date: 10/01/2003
• Status: Expired due to Fees

• Current Assignee: Westport Power Inc. (Westport Fuel Systems, Inc.)
• Original Assignee: Westport Power Inc. (Westport Fuel Systems, Inc.)
• Inventors: Ancimer, Richard, Frazier, Tim, Tanin, Konstantin, Munshi, Sandeep
• Primary Examiner(s): KWON, JOHN
• Application Number:
  US11/397,250
• Publication Number:
  US 20060288979A1
• Time in Patent Office: 672 Days
• Field of Search: 123/299, 123/304, 123/305, 123/435, 123/525, 123/27.GE
• US Class Current: 123/299
• CPC Class Codes: F02B 1/12 with compression ignition with fuel-air charge ignited by compression ignition of an additional fuel F02B7/00
• CPC Class Codes: F02B 23/0675 the combustion space being substantially spherical, hemispherical, ellipsoid or parabolic
• CPC Class Codes: F02D 19/061 by controlling fuel injectors
• CPC Class Codes: F02D 19/0631 by estimation, i.e. without using direct measurements of a corresponding sensor
• CPC Class Codes: F02D 19/10 peculiar to compression-ignition engines in which the main fuel is gaseous
• CPC Class Codes: F02D 35/02 on interior conditions
• CPC Class Codes: F02D 35/021 using an ionic current sensor
• CPC Class Codes: F02D 35/023 by determining the cylinder pressure
• CPC Class Codes: F02D 35/026 using an estimation
• CPC Class Codes: F02D 41/3047 said means being a secondary injection of fuel
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/30 Use of alternative fuels, e.g. biofuels

Abstract

A method and apparatus for controlling to a target heat release rate (HRR) uses an HRR control lever, namely, pilot fuel timing and/or pilot fuel quantity, used in a gaseous-fuelled compression ignition internal combustion engine. The mechanism to control HRR to a target HRR improves engine performance and emissions. A target HRR is determined for a cycle of an engine. An HRR control lever is then used to adjust to the target HRR in consideration of combustion conditions in the engine and the difference between the target HRR and cycle HRR predicted for the cycle by reference to, by way of example, a derived HRR trace from a previous cycle, a pressure trace, a measured property of the exhaust gas directly determined or mapped values provided during calibration allowing for adjustment to a target HRR for the engine. The mapped values can be cross-referenced to engine combustion conditions.

Claims

1. A method of operating a gaseous-fuelled internal combustion engine, said method comprising:

(a) determining a target heat release rate (HRR) for a current cycle of said internal combustion engine;

(b) comparing characteristics of said target HRR to selected characteristics of a trace indicative of an actual HRR for said cycle determined from a previous cycle of said internal combustion engine;

(c) during said cycle of said internal combustion engine;

(i) directing an intake charge into said combustion chamber defined in said engine;

(ii) compressing said intake charge within said combustion chamber;

(iii) introducing at least one gaseous fuel into said combustion chamber;

(iv) introducing a quantity of a pilot fuel into said combustion chamber at a pilot fuel timing, said pilot fuel capable of auto-igniting at a first crank angle when a piston is near or at top dead center within said combustion chamber near completion of a compression stroke during said cycle, said combustion chamber partially defined by said piston;

(v) actuating an HRR control lever to reduce differences between said characteristics of said trace and said characteristics of said target HRR, said HRR control lever comprising at least one of said pilot fuel timing and said quantity of said pilot fuel;

(vi) burning said gaseous fuel and said pilot fuel, said gaseous fuel ignited as a result of combustion of said pilot fuel.

2. The method of claim 1, wherein said characteristics of said trace and said characteristics of said target HRR comprise at least one of:

(a) trace phasing;

(b) absolute trace magnitude;

(c) ratio of trace peak to peak trough;

(d) ratio of trace peak to trace width;

(e) trace width.

3. The method of claim 1, wherein said trace is a controller-processed trace.

4. The method of claim 3, wherein said trace is determined from a pressure trace.

5. The method of claim 3, wherein said trace is determined from an exhaust gas property.

6. The method of claim 5, wherein said exhaust gas property comprises at least one of exhaust gas temperature and exhaust gas composition.

7. The method of claim 1, wherein said gaseous fuel is directly injected into said combustion chamber.

8. The method of claim 7, wherein said gaseous fuel is directly injected into said combustion chamber when said piston is at or near top dead center near completion of said compression stroke during said cycle.

9. The method of claim 8, wherein said gaseous fuel is premixed with said intake charge within an intake manifold prior to ignition of said gaseous fuel.

10. The method of claim 1, wherein said gaseous fuel is introduced into said combustion chamber in a first stage and a second stage.

11. The method of claim 10, wherein said first stage is introduced during at least a portion of one of an intake stroke and said compression stroke during said cycle, said second stage is when said piston is at or near top dead center near completion of said compression stroke.

12. The method of claim 11, wherein said pilot fuel timing is, during said cycle, prior to 50 crank angle degrees before top dead center during said compression stroke.

13. The method of claim 12, wherein said HRR control lever comprises said pilot fuel timing and said pilot fuel quantity.

14. The method of claim 1, wherein said intake charge comprises exhaust gas generated during burning of said gaseous fuel and said pilot fuel in a previous cycle of said engine.

15. The method of claim 1, wherein said pilot fuel timing is later in said cycle than a gaseous fuel timing, said gaseous fuel direct injected into said combustion chamber when said piston is at or near top dead center near completion of a compression stroke during said cycle.

16. The method of claim 1, wherein said pilot fuel timing is adjusted later during said cycle where a methane number of said gaseous fuel increases over a previous cycle methane number.

17. The method of claim 1, wherein said gaseous fuel comprises at least one of methane, hydrogen, ethane and propane.

18. The method of claim 1, wherein timing for introducing said at least one gaseous fuel is one of said HRR control levers.

19. The method of claim 1 further comprising adjusting said pilot fuel timing relative to timing for introducing said at least one gaseous fuel as one of said HRR control levers.

20. The method of claim 19 further comprising operating said engine with EGR levels greater than 30% by mass of said intake charge.

21. The method of claim 19 further comprising operating said engine with EGR levels up to 50% by mass of said intake charge.

22. A control apparatus for controlling heat release rate (HRR) in a gaseous-fuelled direct injection internal combustion engine, said control apparatus comprising:

(a) a controller;

(b) at least one sensor for monitoring a signal, said at least one sensor in communication with a controller capable of processing said signal to provide a trace indicative of an actual HRR;

(c) an HRR control lever, in communication with said controller, said controller capable of adjusting said HRR control lever in response to a difference between said trace and a target HRR.

23. The control apparatus of claim 22, wherein said HRR control lever is at least one of a pilot fuel timing and a pilot fuel quantity, said pilot fuel timing and said pilot fuel quantity actuated by an injector capable of directly injecting a pilot fuel into a combustion chamber of said engine.

24. The control apparatus of claim 22, wherein said HRR control lever is a pilot fuel timing and a pilot fuel quantity, said pilot fuel timing and said pilot fuel quantity actuated by an injector capable of directly injecting a pilot fuel into a combustion chamber of said engine.

25. The control apparatus of claim 22, wherein said at least one sensor comprises an accelerometer.

26. The control apparatus of claim 22, wherein said at least one sensor comprises an in-cylinder pressure sensor.

27. The control apparatus of claim 22, wherein said at least one sensor comprises a strain gauge.

28. The control apparatus of claim 22, wherein said at least one sensor comprises an ion probe.

29. The control apparatus of claim 22, wherein said at least one sensor comprises an exhaust gas temperature sensor.

30. The control apparatus of claim 22, wherein said at least one sensor comprises an in-cylinder fiber optic probe.

31. The control apparatus of claim 22, wherein said controller is programmed to adjust timing for introducing gaseous fuel as one of said HRR control levers.

32. The control apparatus of claim 22, wherein said controller is programmed to adjust pilot fuel timing relative to timing for introducing gaseous fuel as one of said HRR control levers.

33. The control apparatus of claim 32, wherein said controller is programmed to command a valve that regulates mass flow of EGR to operate said engine with EGR levels greater than 30% by mass of said intake charge.

34. The control apparatus of claim 32, wherein said controller is programmed to command a valve that regulates mass flow of EGR to operate said engine with EGR levels up to 50% by mass of said intake charge.